Engage in Energy Efficient Production Saint-Gobain Isover a/s

Transcription

1 Engage in Energy Efficient Production Saint-Gobain Isover a/s

2 Agenda Welcome Introduction to Insulation and Isover a/s Energy Reduction Why? Energy Focus Systematic Approach Energy Reduction in Practice 4 case Small to Large

3 Engage in Energy Efficient Production Saint-Gobain Isover a/s Introduction to Insulation and Isover a/s

4 Saint Gobain Isover a/s In short 100 % owned by Saint-Gobain Dansk Glasuldsfabrik founded in Kastrup Launch for production in the Vamdrup Plant Glasuld a/s acquired by Saint-Gobain Insulation Activity Isover Max yearly production tons ( tons i 2012) Production for Domestic Markets and high flexibility for production for other markets The Vamdrup Plant is one of the most energy efficient plants in the Isover system No. of employees: 195 Turnover: 350 mi. kr. i

5 Part of a Worldwide Group Isover is a part of Saint-Gobain. The Saint-Gobain Group has approx employees in and activities in 50 countries worldwide. Saint-Gobain is divided in 5 sectors: Packaging Float Glass Construction Products High Tech. Products Distribution of Building Materials Isover belong to the Construction Product Sector

6 Plants and R&D Centers

7 The Products of Isover ISOVER produces for a wide range of application different products categories: Building Insualtion Teknical Insulation Flat Roof Insulation Facade Insulation Industrial Insulation (OEM)

8 Process Schematic Energy Consumption Distribution 33 % 6 % 9 % 32 % 6 %

9 Engage in Energy Efficient Production Saint-Gobain Isover a/s Energy Reduction Why?

10 Production Cost by Nature

11 Engage in Energy Efficient Production Saint-Gobain Isover a/s Energy Focus Systematic Approach

12 Energy Management Continous Improvements Systematic Energy management since 1990, DS 2403 certified since 1998, the ISO and now ISO Continuous renew Agreement with DEA on Energy Management and Energy Improvements since 1990 Energy Steering Committee and Action Plans Energy Objectives KPI s and projects KPI follow up Specialist assessments and studies CAPEX based on Energy Reduction Objectives Energy Consumption Mapping Training in Energy Reduction Improving Energy Behavior

13 Continous Improvements Energy Example

14 Energy Committee - Example Integrated part of the ISO Energy Committee: Focus on Energy consumption and reduction Members: Process Engineers, Supervisors Maintenance, HSE coordinator Scope of Work: Effective use of Energy Analysis, Reduction Initiatives, Training Yearly identification, assessment and prioritising reporting Focus the non-technical energy reductions/awareness Management System Operation Lobbyisme support

15 Energy Mapping - Example

16 Engage in Energy Efficient Production Saint-Gobain Isover a/s Practical Cases of Energy Reduction

17 Use of Recycled Glass Waste Reuse Major CAPEX and Major optimization Huge impact The use of recycled glass for production of insulation saves approximately % of the energy used for melting of glass Cullet crushing system Installed in 1994 CAPEX: 3300 kdkk (1994) 750 KDKK Governmental grant Operating cost: Approx. 27 DKK/tons 17

18 Control of Suction from Curing Oven Very small CAPEX and minor optimization Good impact Challenge: Solution: Control of pressure to control flow Energy and Industrial Health Pressure measurement very difficult at very low differentials Measurement by anemometer correlating the pressure to flow Control of dampers on fumes exhaust cascade to the fan 18

19 Compressed Air Systems Major CAPEX Significant optimization Huge impact Delivery of Compressed Air for Process and Utility Principle: Correct relevant pressure Energy optimization Requirement Control Frequency control of 1.3 bar compressors develop together with Atlas Copco System major modified in 1993 Spill over of excessive air 7 bar -> 1,3 bar -> 0,6 bar 19

20 Reduction of Idling consumption No CAPEX Minor optimization Behavior approach Development of Shut Down SOP (Check list) to ensure minimizing of energy consumption during down days 20